EP2712680B1 - Method for coating a workpiece by means of a powder spray gun and powder coating assembly - Google Patents
Method for coating a workpiece by means of a powder spray gun and powder coating assembly Download PDFInfo
- Publication number
- EP2712680B1 EP2712680B1 EP12405107.9A EP12405107A EP2712680B1 EP 2712680 B1 EP2712680 B1 EP 2712680B1 EP 12405107 A EP12405107 A EP 12405107A EP 2712680 B1 EP2712680 B1 EP 2712680B1
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- European Patent Office
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- powder
- width
- coating
- depth
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- 239000011248 coating agent Substances 0.000 title claims description 73
- 238000000576 coating method Methods 0.000 title claims description 73
- 239000000843 powder Substances 0.000 title claims description 51
- 238000000034 method Methods 0.000 title claims description 38
- 229940098458 powder spray Drugs 0.000 title claims description 38
- 238000011156 evaluation Methods 0.000 claims description 17
- 238000005507 spraying Methods 0.000 claims description 7
- 239000007921 spray Substances 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims 1
- 239000010959 steel Substances 0.000 claims 1
- 238000001514 detection method Methods 0.000 description 14
- 238000011161 development Methods 0.000 description 5
- 230000018109 developmental process Effects 0.000 description 5
- 230000003287 optical effect Effects 0.000 description 5
- 238000005259 measurement Methods 0.000 description 4
- 238000009434 installation Methods 0.000 description 2
- 238000013507 mapping Methods 0.000 description 2
- 230000001960 triggered effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
Images
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/4093—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
- B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
- B05B12/12—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to conditions of ambient medium or target, e.g. humidity, temperature position or movement of the target relative to the spray apparatus
- B05B12/122—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to conditions of ambient medium or target, e.g. humidity, temperature position or movement of the target relative to the spray apparatus responsive to presence or shape of target
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
- B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
- B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
- B05B13/0447—Installation or apparatus for applying liquid or other fluent material to conveyed separate articles
- B05B13/0457—Installation or apparatus for applying liquid or other fluent material to conveyed separate articles specially designed for applying liquid or other fluent material to 3D-surfaces of the articles, e.g. by using several moving spray heads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
- B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
- B05B13/0221—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work characterised by the means for moving or conveying the objects or other work, e.g. conveyor belts
- B05B13/0264—Overhead conveying means, i.e. the object or other work being suspended from the conveying means; Details thereof, e.g. hanging hooks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
- B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
- B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
- B05B13/0405—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with reciprocating or oscillating spray heads
- B05B13/041—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with reciprocating or oscillating spray heads with spray heads reciprocating along a straight line
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B5/00—Electrostatic spraying apparatus; Spraying apparatus with means for charging the spray electrically; Apparatus for spraying liquids or other fluent materials by other electric means
- B05B5/08—Plant for applying liquids or other fluent materials to objects
- B05B5/081—Plant for applying liquids or other fluent materials to objects specially adapted for treating particulate materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B5/00—Electrostatic spraying apparatus; Spraying apparatus with means for charging the spray electrically; Apparatus for spraying liquids or other fluent materials by other electric means
- B05B5/08—Plant for applying liquids or other fluent materials to objects
- B05B5/082—Plant for applying liquids or other fluent materials to objects characterised by means for supporting, holding or conveying the objects
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/45—Nc applications
- G05B2219/45013—Spraying, coating, painting
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- the invention relates to a method and an apparatus for coating a workpiece with powder coating.
- This is an electrostatic powder coating in which the workpiece to be coated is coated with a layer of electrostatically charged powder.
- the powder-coated workpiece is heated so that the powder liquefies on the surface of the workpiece, then hardens and forms a closed layer.
- An object of the invention is to specify a method for coating a workpiece with powder by means of a powder spray gun, which automatically determines the geometry of the workpiece to be coated and automatically determines the coating parameters required for the coating.
- the inventive method is easy and inexpensive to implement even in an existing powder coating system.
- An existing system can therefore be easily retrofitted.
- no or only a few components need to be replaced.
- the object is achieved by a method for coating a workpiece with powder by means of a powder spray device having the features specified in claim 1.
- the depth of the workpiece and the width of the workpiece are detected.
- any existing depressions in the workpiece are detected.
- coating parameters for the powder spray device are determined on the basis of the width, the depth and the depressions. The workpiece is then coated with the coating parameters determined for this purpose.
- the powder coating apparatus which can be operated by the method described above, comprises an optical detection device for the depth and the width of the workpiece, a computing unit and a powder spray device.
- the coating parameters are the high voltage and / or the spray stream and / or the atomizing air and / or the powder quantity and / or the triggering of the powder spray device and / or the conveying air and / or the metering air and / or the distance between the workpiece and the powder spraying device and / or the vertical position of the powder spraying device and / or the visible side of the workpiece and / or the back of the workpiece and / or the powder type and / or or the conductivity of the workpiece and / or the transport speed of the workpiece and / or whether the workpiece is precoated.
- the detected depth of the workpiece is assigned to one of several classes for the depth.
- the detected width of the workpiece is assigned to one of several classes for the width.
- the recess of the workpiece is assigned to one of several classes for the recess.
- an automatic powder spray gun can be used as powder spray gun.
- the depth, the width and the depressions can be detected with an optical sensor.
- the width of the workpiece is calculated in a simple manner.
- a program number is automatically generated from the class for the width and / or the class for the depth and / or the class for the depressions.
- the coating parameters for the powder spray gun and / or the powder pump are determined on the basis of the program number.
- the transport device for the workpiece is provided, wherein the depth detection device is arranged and operable to detect the depth of the workpiece in the vicinity of the transport device.
- an incremental encoder is provided to detect the position of the workpiece.
- the depth detection device is optical Sensor, a laser probe, a line scanner, a lathe scanner or a camera.
- FIG. 1 a possible embodiment of the powder coating system 1 is shown in a three-dimensional view. In order to facilitate the understanding of the invention, the components are shown simplified.
- the workpieces 100, 101, 102 to be coated hang on a transport device 2 and are transported in the transport direction TR.
- the powder coating system 1 which is also referred to below as a coating unit in short, comprises a detection device with which the geometry and the position of the workpiece 100 to be coated is determined. As soon as the workpiece 100 to be coated passes the detection device, its width and its depth are determined.
- the detection device has for this purpose a sensor 3, which is mounted on a holder 4 and detects the geometry of the front side of the workpiece 100.
- the detection device also has a sensor 5, which is mounted on a holder 6 and detects the geometry of the rear side of the workpiece 100.
- the area of the coating installation 1 in which the automatic coating takes place is also referred to as a coating station.
- a powder spray device or briefly spray device with one or more parallel juxtaposed powder spray guns 8 and 9, respectively FIG. 1 not shown guide arms attached.
- the two guide arms are designed so that the powder spray guns 8 and 9 both in the vertical direction, which is also referred to below as the z-direction, as well as in the horizontal direction transversely to the transport direction TR of the workpiece 100, which is also referred to below as the y-direction, are movable.
- the powder spray guns 8 and 9 can be arranged in one or more rows. For example, five powder spray guns may each be arranged in two rows on one side of the coating station and five powder spray guns each in two rows on the other side of the coating station. In FIG. 1 four powder spray guns 8 and four powder spray guns 9 are each arranged in a single row. If necessary, the powder spray guns 8 and 9 can also be attached to a linear lifting device 15 (in FIG FIG. 2 shown schematically) to be attached. With the Linearhub réelle 15, the powder spray guns can be moved vertically and horizontally.
- the powder coating system 1 may well have additional components in addition to the components shown.
- a coating booth can be provided in which the powder spray guns 8 and 9 are arranged or in which the powder spray guns 8 and 9 protrude.
- FIG. 2 shows the powder coating system in a schematic representation.
- the control of the entire powder coating device via a control unit 12.
- the control of each gun is done via a control unit.
- the controller controls the voltage, current, and amount of powder sprayed from the gun connected to the controller.
- FIG. 2 is shown by way of example that the gun 9 is controlled via a control unit 13 and the gun 8 via a control unit 14.
- FIG. 3 shows a possible sequence of the inventive method in a flow chart.
- the detection of the depth, the width and the recesses and the position of the workpiece can be done in various ways. In the following, this will be explained by way of example with reference to three embodiments.
- the two sensors 3 and 5 are designed as optical distance sensors and detect during the time period T during which the workpiece 100 is transported past them, at different times t pointwise the distance d to the workpiece 100.
- each sensor 3, 5 a Scanning profile A (t, d) with a series of measuring points.
- the sensor 3 supplies the measuring points as scanning profile A (t, d3)
- a t . d ⁇ 3 t ⁇ 1 . d ⁇ 31 . t ⁇ 2 . d ⁇ 32 . ... tn . d ⁇ 3 ⁇ n ,
- the sensor 5 supplies the measuring points as scanning profile A (t, d5)
- a t . d ⁇ 5 t ⁇ 1 . d ⁇ 51 . t ⁇ 2 . d ⁇ 52 . ... tn . d ⁇ 5 ⁇ n ,
- sampling profiles A (t, d3) and A (t, d5) are assigned to an evaluation unit 10 (see FIG. 2 ).
- the evaluation unit 10 additionally receives the measurement signal series P (t, x).
- the evaluation unit 10 can determine the total width s 2 of the workpiece 100 from the measurement series P (t, x).
- the evaluation unit 10 determines the geometry of the front side of the workpiece 100 from the scanning profile A (t, d3).
- the geometry is also referred to here as the profile of the workpiece.
- the evaluation unit 10 determines the geometry of the rear side of the workpiece 100 from the scanning profile A (t, d5).
- FIG. 4 in the view from above shown workpiece 103 has a rectangular cross-section. While the workpiece 103 is moved between the two sensors 3 and 5, they measure, as mentioned above, at certain times t1 ... tn respectively the distance d3 or d5 to the workpiece 103. From the distance measured values d31 ... d3n and d51 ... d5n, the evaluation unit 10 can now calculate the total depth s1 of the workpiece 103. This corresponds to step 21 in the flowchart according to FIG FIG. 3 ,
- the total depth s1 is assigned to one of several classes KT1... KTn for the total depth.
- Each of the classes KT represents a value subarea. If, for example, three classes KT1, KT2 and KT3 are provided with equal value subareas, the total depth s1 is assigned to class KT1 if s1 is between 0 and 33% of the nominal value. If the total depth s1 is between 33% and 66% of the nominal size, the total depth s1 is assigned to class KT2. If s1 is between 66% and 100% of the nominal size, s1 is assigned to class KT3.
- the nominal dimension is that value which corresponds to the maximum possible distance detectable by the sensors 3 and 5.
- the nominal size depends essentially on the structural conditions such as the distance between the two sensors 3 and 5 from.
- the number of definable classes KT1... KTn depends inter alia on the desired detection accuracy and can in principle be freely determined.
- the division of the nominal size range (0% to 100% of the nominal size) into classes KT1 to KTn is also freely selectable. Basically, the nominal size range does not need to be divided into n equal parts. It is also possible, for example, the nominal size range to divide so that certain classes represent a larger and others in turn a smaller portion of the nominal size range.
- the classes KB1 to KB4 could also be divided with absolute values, such as mm or increments.
- the total width s2 is now assigned to the class KB1 ... KB4, in whose value range the total width s2 falls.
- the dimension s3 0, so that the workpiece 103 is assigned to the recesses of the class KV1.
- the assignment Z (KT3, KB1, KV1) results for the workpiece 103.
- the classes KT3, KB1 and KV1 thus form the characteristics for the geometry of the workpiece 103.
- the conductivity of the workpiece and / or the transport speed of the workpiece may also be coating parameters. This enumeration is just a selection and not an exhaustive list of operating parameters.
- the determination of the optimum operating parameters P1... Pn for a particular workpiece can be found by a series of tests.
- This phase is a kind of learning phase. If the optimum operating parameters P1... Pn have been found for a particular workpiece geometry, these are stored together with the characteristics of the workpiece geometry KT, KB and KV and assigned a unique program number PRG. If you do this for different workpieces, you can create the following table, for example: workpiece Workpiece characteristics Program No. Front Program No. Backside 130 KT1, KB1, KV1, KV2 111 112 164 KT1, KB1, KV2, KV1 112 111 201 KT3, KB2, KV1, KV1 321 321 etc.
- the control unit 12 determines from these characteristics the program number PRG121 for the front side and the program number PRG121 for the back side (step 27), and sets the coating parameters P1 ... P9 for the workpiece 103 accordingly (step 28).
- the control unit 12 determines from these characteristics the program number PRG232 for the front side and the program number PRG231 for the rear side and sets the coating parameters P1 ... P9 for the workpiece 104 accordingly.
- the control unit 12 determines from these characteristics the program number PRG232 for the front side and the program number PRG231 for the rear side and sets the coating parameters P1... P9 for the workpiece 105 accordingly.
- control unit 12 causes the coating parameters P1... P9 matching the workpiece to be set and the workpiece to be optimally coated.
- the workpiece profiles shown in the figures are only examples.
- the workpiece may also have more than one recess on the front and the back.
- any number of depressions in the workpiece can be measured.
- the number of recesses recorded is a measure of the complexity of the workpiece and can be taken into account as a further coating parameter when selecting the appropriate program number. For example, if less than five indentations are detected on one side of the workpiece, the workpiece can be considered to be of little complexity. If five or more recesses are detected on one side of the workpiece, the workpiece can be classified as complex.
- the detection of the workpiece profile can be done immediately before the coating station or well before. If the workpiece profile is detected well in front of the coating station, it is also ensured, among other things, that the sensors do not become contaminated by the excess powder. The order in which the various workpieces reach the coating station, does not matter. The control unit 12 remembers the order in which the workpieces were detected and can then take this into account during coating.
- the detection of the width, the depth and the depressions can also be done in the following manner.
- the two sensors 3 and 5 are designed as optical line scanners and detect during the period T, during which the workpiece 100 is transported past them, not only pointwise but line by line the workpiece 100. In this way arises at time t1 the scan the entire scanning profile A (t1, d) of the workpiece.
- the sensor 3 supplies the measuring points as scanning profile A (t1, d3)
- a t . d ⁇ 3 t ⁇ 1 . d ⁇ 31 . t ⁇ 2 . d ⁇ 32 . ... tn . d ⁇ 3 ⁇ n ,
- the sensor 5 supplies the measuring points as scanning profile A (t1, d5)
- a t . d ⁇ 5 t ⁇ 1 . d ⁇ 51 . t ⁇ 2 . d ⁇ 52 . ... tn . d ⁇ 5 ⁇ n ,
- These two scanning profiles A (t1, d3) and A (t1, d5) are fed to the evaluation unit 10.
- no separate sensor 7 for detecting the workpiece width is present here.
- the evaluation unit 10 can determine both the total depth s1 and the total width s2 of the workpiece 100.
- the evaluation unit 10 additionally determines the geometry of the front side of the workpiece 100 from the scanning profile A (t1, d3).
- the evaluation unit 10 determines the geometry of the rear side of the workpiece 100 from the scanning profile A (t1, d5).
- the width of the workpiece is determined with an incremental encoder.
- the sensor 7 as an incremental encoder be educated.
- the incremental encoder generates pulses or increments.
- a start pulse is triggered which signals the front end of the workpiece.
- an end pulse is triggered which signals the rear end of the workpiece.
- the width of the workpiece can be calculated in a simple manner. Under certain circumstances, even the number of increments occurring between the start and the end pulse can be sufficient to conclude the width of the workpiece. In this case, the workpiece then has a width which corresponds to the number of increments occurring between the start and the end pulse. The measure for the workpiece width is then the number of increments.
- the detection of the depth and the recesses of the workpiece can be carried out in the manner described above under embodiment 1 or 2.
- elongate profiles are suitable as workpieces with substantially constant cross-section over the length, such as construction profiles for conservatories.
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Description
Die Erfindung betrifft ein Verfahren und eine Vorrichtung zum Beschichten eines Werkstücks mit Pulverlack. Dabei handelt es sich um eine elektrostatische Pulverbeschichtung, bei der das zu beschichtende Werkstück mit einer Schicht elektrostatisch aufgeladenem Pulver überzogen wird. In einem sich daran anschließenden Arbeitsgang wird das mit dem Pulver beschichtete Werkstück erwärmt, sodass sich das Pulver auf der Oberfläche des Werkstücks verflüssigt, anschliessend aushärtet und eine geschlossene Schicht bildet.The invention relates to a method and an apparatus for coating a workpiece with powder coating. This is an electrostatic powder coating in which the workpiece to be coated is coated with a layer of electrostatically charged powder. In a subsequent operation, the powder-coated workpiece is heated so that the powder liquefies on the surface of the workpiece, then hardens and forms a closed layer.
Um verschieden geformte Werkstücke, die in beliebiger Reihenfolge zur Beschichtungsanlage gelangen, automatisch, das heisst nicht manuell, beschichten zu können, wird vorgeschlagen, dass die Geometrie der Werkstücke vor der Beschichtung ermittelt wird und dann die Beschichtungsparameter entsprechend eingestellt werden. Dadurch wird die Beschichtungsanlage flexibler einsetzbar.In order to be able to coat differently shaped workpieces, which arrive in any order to the coating installation, automatically, ie not manually, it is proposed that the geometry of the workpieces is determined before the coating and then the coating parameters are adjusted accordingly. This makes the coating system more flexible.
Aus dem Stand der Technik
Eine Aufgabe der Erfindung ist es ein Verfahren zur Beschichtung eines Werkstücks mit Pulver mittels einer Pulversprühpistole anzugeben, das automatisch die Geometrie des zu beschichtenden Werkstücks ermittelt und die für die Beschichtung erforderlichen Beschichtungsparameter automatisch festlegt.An object of the invention is to specify a method for coating a workpiece with powder by means of a powder spray gun, which automatically determines the geometry of the workpiece to be coated and automatically determines the coating parameters required for the coating.
Vorteilhafter Weise ist das erfindungsgemässe Verfahren auch bei einer bereits bestehenden Pulverbeschichtungsanlage einfach und kostengünstig zu implementieren. Eine bestehende Anlage kann also problemlos nachgerüstet werden. In der Regel müssen keine oder nur wenige Komponenten ausgewechselt werden.Advantageously, the inventive method is easy and inexpensive to implement even in an existing powder coating system. An existing system can therefore be easily retrofitted. As a rule, no or only a few components need to be replaced.
Die Aufgabe wird durch ein Verfahren zur Beschichtung eines Werkstücks mit Pulver mittels einer Pulversprühvorrichtung mit den in Patentanspruch 1 angegebenen Merkmalen gelöst.The object is achieved by a method for coating a workpiece with powder by means of a powder spray device having the features specified in
Bei dem erfindungsgemässen Verfahren zur Beschichtung eines Werkstücks mit Pulver mittels einer Pulversprühvorrichtung, werden die Tiefe des Werkstücks und die Breite des Werkstücks erfasst. Zudem werden eventuell vorhandene Vertiefungen im Werkstück erfasst. Mittels einer Steuereinheit werden anhand der Breite, der Tiefe und der Vertiefungen Beschichtungsparameter für die Pulversprühvorrichtung bestimmt. Das Werkstück wird dann mit den dafür ermittelten Beschichtungsparametern beschichtet.In the method according to the invention for coating a workpiece with powder by means of a powder spraying device, the depth of the workpiece and the width of the workpiece are detected. In addition, any existing depressions in the workpiece are detected. By means of a control unit, coating parameters for the powder spray device are determined on the basis of the width, the depth and the depressions. The workpiece is then coated with the coating parameters determined for this purpose.
Die Aufgabe wird zudem durch eine Pulverbeschichtungsanlage mit den in Patentanspruch 12 angegebenen Merkmalen gelöst.The object is also achieved by a powder coating system having the features specified in
Die erfindungsgemässe Pulverbeschichtungsanlage, die mit dem oben beschriebenen Verfahren betreibbar ist, umfasst eine optische Erfassungseinrichtung für die Tiefe und die Breite des Werkstücks, eine Recheneinheit und eine Pulversprühvorrichtung.The powder coating apparatus according to the invention, which can be operated by the method described above, comprises an optical detection device for the depth and the width of the workpiece, a computing unit and a powder spray device.
Vorteilhafte Weiterbildungen der Erfindung ergeben sich aus den in den abhängigen Patentansprüchen angegebenen Merkmalen.Advantageous developments of the invention will become apparent from the features indicated in the dependent claims.
Bei einer Weiterbildung des erfindungsgemässen Verfahrens sind die Beschichtungsparameter die Hochspannung und/oder der Sprühstrom und/oder die Zerstäuberluft und/oder die Pulvermenge und/oder die Triggerung der Pulversprühvorrichtung und/oder die Förderluft und/oder die Dosierluft und/oder der Abstand zwischen dem Werkstück und der Pulversprühvorrichtung und/oder die vertikale Position der Pulversprühvorrichtung und/oder die Sichtseite des Werkstücks und/oder die Rückseite des Werkstücks und/oder die Pulverart und/oder die Leitfähigkeit des Werkstücks und/oder die Transportgeschwindigkeit des Werkstücks und/oder ob das Werkstück vorbeschichtet ist.In a development of the method according to the invention, the coating parameters are the high voltage and / or the spray stream and / or the atomizing air and / or the powder quantity and / or the triggering of the powder spray device and / or the conveying air and / or the metering air and / or the distance between the workpiece and the powder spraying device and / or the vertical position of the powder spraying device and / or the visible side of the workpiece and / or the back of the workpiece and / or the powder type and / or or the conductivity of the workpiece and / or the transport speed of the workpiece and / or whether the workpiece is precoated.
Bei einer anderen Weiterbildung des erfindungsgemässen Verfahrens wird die erfasste Tiefe des Werkstücks einer von mehreren Klassen für die Tiefe zugeordnet.In another development of the method according to the invention, the detected depth of the workpiece is assigned to one of several classes for the depth.
Bei einer Ausführungsform des erfindungsgemässen Verfahrens wird die erfasste Breite des Werkstücks einer von mehreren Klassen für die Breite zugeordnet.In one embodiment of the method according to the invention, the detected width of the workpiece is assigned to one of several classes for the width.
Bei einer anderen Ausführungsform des erfindungsgemässen Verfahrens wird die Vertiefung des Werkstücks einer von mehreren Klassen für die Vertiefung zugeordnet.In another embodiment of the method according to the invention, the recess of the workpiece is assigned to one of several classes for the recess.
Zudem kann bei dem erfindungsgemässen Verfahren als Pulversprühpistole eine automatische Pulversprühpistole benutzt werden.In addition, in the method according to the invention, an automatic powder spray gun can be used as powder spray gun.
Bei dem erfindungsgemässen Verfahren können die Tiefe, die Breite und die Vertiefungen mit einem optischen Sensor erfasst werden.In the method according to the invention, the depth, the width and the depressions can be detected with an optical sensor.
Darüber hinaus kann bei dem erfindungsgemässen Verfahren vorgesehen sein, dass auch die Position des Werkstückes erfasst wird.In addition, it can be provided in the inventive method that the position of the workpiece is detected.
Zudem ist es von Vorteil mit Hilfe eines Inkrementalgebers die Breite des Werkstückes zu ermitteln. Anhand der vom Inkrementalgeber gelieferten Inkremente, die zwischen einem Start- und einem Endimpuls liegen, wird auf einfache Weise die Breite des Werkstücks errechnet.In addition, it is advantageous with the help of an incremental encoder to determine the width of the workpiece. Based on the incremental encoder supplied increments between a start and a final pulse, the width of the workpiece is calculated in a simple manner.
Vorteilhafterweise wird bei dem erfindungsgemässen Verfahren aus der Klasse für die Breite und/oder der Klasse für die Tiefe und/oder der Klasse für die Vertiefungen automatisch eine Programmnummer erstellt.Advantageously, in the method according to the invention, a program number is automatically generated from the class for the width and / or the class for the depth and / or the class for the depressions.
Bei dem erfindungsgemässen Verfahren kann vorgesehen sein, dass anhand der Programmnummer die Beschichtungsparameter für die Pulversprühpistole und/oder die Pulverpumpe bestimmt werden.In the method according to the invention it can be provided that the coating parameters for the powder spray gun and / or the powder pump are determined on the basis of the program number.
Zudem kann bei dem erfindungsgemässen Verfahren vorgesehen sein, dass die Vertiefungen auf der Vorderseite und auf der Rückseite des Werkstückes erfasst werden.In addition, it can be provided in the method according to the invention that the depressions on the front side and on the rear side of the workpiece are detected.
Bei einer Weiterbildung der Pulverbeschichtungsanlage ist der eine Transporteinrichtung für das Werkstück vorgesehen, wobei die Erfassungseinrichtung für die Tiefe derart angeordnet und betreibbar ist, dass es die Tiefe des Werkstücks in der Nähe der Transporteinrichtung erfasst.In a further development of the powder coating system, the transport device for the workpiece is provided, wherein the depth detection device is arranged and operable to detect the depth of the workpiece in the vicinity of the transport device.
Bei einer anderen Weiterbildung der Pulverbeschichtungsanlage ist ein Inkrement-Encoder vorgesehen, um die Position des Werkstückes zu erfassen.In another development of the powder coating system, an incremental encoder is provided to detect the position of the workpiece.
Bei einer Ausführungsform der Pulverbeschichtungsanlage ist die Erfassungseinrichtung für die Tiefe ein optischer Sensor, ein Laser-Taster, ein Linienscanner, ein Drehstahlscanner oder eine Kamera.In one embodiment of the powder coating system, the depth detection device is optical Sensor, a laser probe, a line scanner, a lathe scanner or a camera.
Im Folgenden wird die Erfindung anhand von 5 Figuren weiter erläutert.
Figur 1- zeigt eine mögliche Ausführungsform der Pulverbeschichtungsanlage in einer dreidimensionalen Ansicht.
Figur 2- zeigt die Pulverbeschichtungsanlage in einer Prinzipdarstellung.
Figur 3- zeigt einen möglichen Ablauf des erfindungsgemässen Verfahrens in einem Flussdiagramm.
Figur 4- zeigt die Sensoranordnung der Pulverbeschichtungsanlage zusammen mit einem ersten zu vermessenden Werkstück in der Draufsicht.
Figur 5- zeigt die Sensoranordnung zusammen mit einem zweiten zu vermessenden Werkstück in der Draufsicht.
- Figur 6
- zeigt die Sensoranordnung zusammen mit einem dritten zu vermessenden Werkstück in der Draufsicht.
- FIG. 1
- shows a possible embodiment of the powder coating system in a three-dimensional view.
- FIG. 2
- shows the powder coating system in a schematic representation.
- FIG. 3
- shows a possible sequence of the inventive method in a flow chart.
- FIG. 4
- shows the sensor arrangement of the powder coating system together with a first workpiece to be measured in plan view.
- FIG. 5
- shows the sensor assembly together with a second workpiece to be measured in plan view.
- FIG. 6
- shows the sensor assembly together with a third workpiece to be measured in plan view.
In
Die zu beschichtenden Werkstücke 100, 101, 102 hängen an einer Transporteinrichtung 2 und werden in Transportrichtung TR transportiert.The
Die Pulverbeschichtungsanlage 1, die im Folgenden auch kurzum als Beschichtungsanlage bezeichnet wird, umfasst eine Erfassungseinrichtung mit der die Geometrie und die Position des zu beschichtenden Werkstücks 100 ermittelt wird. Sobald das zu beschichtende Werkstück 100 die Erfassungseinrichtung passiert, wird dessen Breite und dessen Tiefe ermittelt. Die Erfassungseinrichtung weist dazu einen Sensor 3 auf, der an einer Halterung 4 montiert ist und die Geometrie der Vorderseite des Werkstücks 100 erfasst. Die Erfassungseinrichtung weist zudem einen Sensor 5 auf, der an einer Halterung 6 montiert ist und die Geometrie der Rückseite des Werkstücks 100 erfasst.The
Der Bereich der Beschichtungsanlage 1, in dem die automatische Beschichtung erfolgt, wird auch als Beschichtungsstation bezeichnet. Dort befindet sich eine Pulversprühvorrichtung oder kurz Sprühvorrichtung mit einer oder mehreren parallel nebeneinander angeordneten Pulversprühpistolen 8 bzw. 9. Diese können an zwei in
Die Pulversprühpistolen 8 und 9 können ein- oder mehrreihig angeordnet sein. Es können beispielsweise jeweils fünf Pulversprühpistolen in zwei Reihen auf der einen Seite der Beschichtungsstation und jeweils fünf Pulversprühpistolen in zwei Reihen auf der anderen Seite der Beschichtungsstation angeordnet sein. In
Die Pulverbeschichtungsanlage 1 kann neben den gezeigten Komponenten durchaus auch noch zusätzliche Komponenten aufweisen. So kann beispielsweise eine Beschichtungskabine vorgesehen sein, in der die Pulversprühpistolen 8 und 9 angeordnet sind oder in die die Pulversprühpistolen 8 und 9 hineinragen.The
Der Teil des Pulvers, der nicht am zu beschichtenden Werkstück 100 haften bleibt, wird über einen ebenfalls nicht gezeigten Absaugkanal aus der Kabine abgesaugt und in einem Behälter gesammelt. Auch wenn für die Beschichtung der Werkstücke eine Kabine von Vorteil ist, so ist diese jedoch nicht zwingend erforderlich. Auch für die Absaugung des überschüssigen Pulvers ist grundsätzlich keine Kabine erforderlich. Das abgesaugte überschüssige Pulver kann erneut für die Beschichtung verwendet werden.
Die Steuerung der gesamten Pulverbeschichtungsvorrichtung erfolgt über eine Steuereinheit 12. Die Steuerung der einzelnen Pistolen erfolgt jeweils über ein Steuergerät. Das Steuergerät regelt insbesondere die Spannung, den Strom und die Pulvermenge, die von der an das Steuergerät angeschlossenen Pistole versprüht wird. In
Die Erfassung der Tiefe, der Breite und der Vertiefungen sowie der Position des Werkstücks kann auf verschiedene Arten erfolgen. Im Folgenden wird dies anhand von drei Ausführungsformen beispielhaft erläutert.The detection of the depth, the width and the recesses and the position of the workpiece can be done in various ways. In the following, this will be explained by way of example with reference to three embodiments.
Die beiden Sensoren 3 und 5 sind als optische Abstandssensoren ausgebildet und erfassen während der Zeitdauer T während der das Werkstück 100 an ihnen vorbei transportiert wird, zu verschiedenen Zeitpunkten t punktweise den Abstand d zum Werkstück 100. Auf diese Weise erzeugt jeder Sensor 3, 5 ein Abtastprofil A(t, d) mit einer Reihe von Messpunkten. Der Sensor 3 liefert als Abtastprofil A(t, d3) die Messpunkte
Der Sensor 5 liefert als Abtastprofil A(t, d5) die Messpunkte
Zusätzlich befindet sich oben in der Nähe der Transporteinrichtung 2 ein weiterer Sensor 7, der die Position x des Werkstücks 100 in Abhängigkeit von der Zeit ermittelt. Der Sensor 7 erzeugt somit die Messsignalreihe P(t, x) :
Diese beiden Abtastprofile A(t, d3) und A(t, d5) werden einer Auswerteeinheit 10 (siehe
Im Folgenden wird die Bestimmung der Profile für die Vorder- und die Rückseite jener Werkstücke 103, 104 und 105 beispielhaft weiter erläutert, die in den
Das in
Anschliessend wird im Schritt 22 die Gesamttiefe s1 einer von mehreren Klassen KT1 ... KTn für die Gesamttiefe zugeordnet. Jede der Klassen KT repräsentiert dabei einen Werteteilbereich. Sind beispielsweise drei Klassen KT1, KT2 und KT3 mit gleich grossen Werteteilbereichen vorgesehen, so wird die Gesamttiefe s1 der Klasse KT1 zugeordnet, wenn s1 zwischen 0 und 33% des Nennmasses liegt. Wenn die Gesamttiefe s1 zwischen 33% und 66% des Nennmasses liegt, wird die Gesamttiefe s1 der Klasse KT2 zugeordnet. Liegt s1 im Bereich zwischen 66% und 100% des Nennmasses, wird s1 der Klasse KT3 zugeordnet.Subsequently, in
Als Nennmass wird jener Wert verstanden, der dem maximal möglichen, mit den Sensoren 3 und 5 erfassbaren Abstand entspricht. Das Nennmass hängt im Wesentlichen von den baulichen Gegebenheiten wie beispielsweise dem Abstand der beiden Sensoren 3 und 5 ab. Die Anzahl der definierbaren Klassen KT1 ... KTn hängt unter anderem von der gewünschten Erfassungsgenauigkeit ab und ist grundsätzlich frei bestimmbar. Auch die Aufteilung des Nennmassbereichs (0% bis 100% des Nennmasses) auf die Klassen KT1 bis KTn ist frei wählbar. Grundsätzlich braucht der Nennmassbereich nicht in n gleich grosse Teilbereiche aufgeteilt zu werden. Es ist beispielsweise auch möglich, den Nennmassbereich so aufzuteilen, dass bestimmte Klassen einen grösseren und andere wiederum einen kleineren Teilbereich des Nennmassbereichs repräsentieren.The nominal dimension is that value which corresponds to the maximum possible distance detectable by the
Die Erfassung der Gesamtbreite s2 erfolgt im Schritt 23. Wie bei der Gesamttiefe s1 wird auch die Gesamtbreite s2 einer von mehreren Klassen KB1 ... KBn für die Gesamtbreite zugeordnet (Schritt 24). Die Zuordnung der Gesamtbreite s2 zu einer der Klassen KB1 ... KBn kann sinngemäss auf die oben beschriebene Art und Weise erfolgen. Die maximal mögliche erfassbare Breite wird als Nennbreitenmass definiert. Die Klassen KB1 ... KBn können beispielsweise wie folgt aufgeteilt werden.
- KB1: 0
% bis 25% des Nennbreitenmasses - KB2: 25% bis 50% des Nennbreitenmasses
- KB3: 50% bis 75% des Nennbreitenmasses
- KB4: 75
% bis 100% des Nennbreitenmasses
- KB1: 0% to 25% of the nominal width dimension
- KB2: 25% to 50% of the nominal width dimension
- KB3: 50% to 75% of the nominal width
- KB4: 75% to 100% of the nominal width dimension
Statt die Klassen KB1 bis KB4 mit Relativwerten (Prozentwerten) aufzuteilen, könnten die Klassen KB1 bis KB4 auch mit Absolutwerten, wie zum Beispiel mm oder Inkrementen aufgeteilt werden.Instead of dividing the classes KB1 to KB4 with relative values (percentages), the classes KB1 to KB4 could also be divided with absolute values, such as mm or increments.
Die Gesamtbreite s2 wird nun jener Klasse KB1 ... KB4 zugeordnet, in dessen Wertebereich die Gesamtbreite s2 fällt.The total width s2 is now assigned to the class KB1 ... KB4, in whose value range the total width s2 falls.
Schliesslich werden auch für Vertiefungen wie zum Beispiel s3, s4 mehrere Klassen KV1 ... KVn definiert (Schritt 26 im Flussdiagramm). Werden dafür beispielsweise zwei Klassen KV1 und KV2 vorgesehen, können diese wie folgt definiert werden:
- KV1:
- KV2:
- KV1:
- KV2:
Da das Werkstück 103 weder auf der Vorder- noch auf der Rückseite Vertiefungen aufweist, ist das Mass s3 = 0, so dass das Werkstück 103 bezüglich der Vertiefungen der Klasse KV1 zugeordnet wird.Since the
Für das Werkstück 103 ergibt sich beispielsweise die Zuordnung Z = (KT3, KB1, KV1). Die Klassen KT3, KB1 und KV1 bilden somit die Charakteristika für die Geometrie des Werkstücks 103.For example, the assignment Z = (KT3, KB1, KV1) results for the
Für jedes Werkstückprofil gibt es ein optimales Betriebsprogramm, das heisst einen optimalen Satz an Betriebsparametern P1 ... Pn, die im Folgenden auch als Beschichtungsparameter bezeichnet werden. Dazu gehören die vom Hochspannungsgenerator erzeugte Hochspannung P1 und der durch die Hochspannungselektrode fliessende Sprühstrom P2. Aber auch die Zerstäuberluft P3, die Pulvermenge P4 und die Triggerung der Pulversprühpistole P5, also das Ein- und Ausschalten des Pulverstroms, sind mögliche Beschichtungsparameter. Zudem sind die Förderluft P6, die Dosierluft P7 der Pulver-Injektoren 14 oder der Pulverpumpen, der Abstand P8 zwischen dem Werkstück 103 und der Pulversprühpistole 8 und die vertikale Position P9 der Pulversprühpistole 8 mögliche Beschichtungsparameter. Auch ob das Werkstück vorbeschichtet ist, kann ein Beschichtungsparameter sein. Weitere Beschichtungsparameter können sein ob es sich um die Sichtseite des Werkstücks handelt und/oder ob es sich um die Rückseite des Werkstücks handelt. Darüber hinaus kann auch die Pulverart einen Beschichtungsparameter darstellen. Hierbei kann die Pulverart beispielsweise in verschiedene Klassen eingeteilt werden, wie:
- Organische und anorganische Pulver,
- Metallic- und nicht Metallicpulver,
- Strukturbildendes oder glatt verlaufendes Pulver,
- Farbklasse oder Deckungskraft des Pulvers,
- Dielektrizitätsklasse des Pulvers,
- Spezifisches Gewicht des Pulvers,
- einfach handhabbares oder komplexes Pulver.
- Organic and inorganic powders,
- Metallic and not metallic powder,
- Structure-forming or smooth-running powder,
- Color class or opacity of the powder,
- Dielectric class of the powder,
- Specific weight of powder,
- easy to handle or complex powder.
Auch die Leitfähigkeit des Werkstücks und/oder die Transportgeschwindigkeit des Werkstücks können Beschichtungsparameter sein. Diese Aufzählung ist lediglich eine Auswahl und keine abschliessende Aufzählung der Betriebsparameter.The conductivity of the workpiece and / or the transport speed of the workpiece may also be coating parameters. This enumeration is just a selection and not an exhaustive list of operating parameters.
Bevor die Beschichtungsanlage mit der automatischen Beschichtung der Werkstücke beginnt, kann die Ermittlung der für ein bestimmtes Werkstück optimalen Betriebsparameter P1 ... Pn beispielsweise durch eine Reihe von Versuchen herausgefunden werden. Diese Phase ist eine Art Lernphase. Hat man für eine bestimmte Werkstückgeometrie die optimalen Betriebsparameter P1 ... Pn gefunden, werden diese zusammen mit den Charakteristika der Werkstückgeometrie KT, KB und KV abgespeichert und ihnen eine eindeutige Programmnummer PRG zugeordnet. Führt man dies für verschiedene Werkstücke durch, kann daraus beispielsweise die folgende Tabelle entstehen:
Somit kann anhand der Tabelle für die verschiedensten Werkstückprofile jeweils die entsprechende Programmnummer und damit der Satz mit den optimalen Betriebsparametern P1 ... Pn ausgewählt werden.Thus, in each case the corresponding program number and thus the set with the optimum operating parameters P1... Pn can be selected on the basis of the table for the most varied workpiece profiles.
Im Folgenden wird die Bestimmung der Programmnummer PRG anhand von drei Beispielen mit drei verschiedenen Werkstücken 103 (siehe
- KV1:
- KV2:
- KV2:
- KV1:
- KV2:
- KV2:
Diese Initialisierung erfolgt im Flussdiagramm in
Bei der Erfassung der Tiefe, der Breite und der Vertiefungen des in
- s1 = 90 mm
- s2 = 340 mm
- s3 = 0 mm
- s4 = 0 mm
- s5 = 0 mm
- s6 = 0 mm
- s1 = 90 mm
- s2 = 340 mm
- s3 = 0 mm
- s4 = 0 mm
- s5 = 0 mm
- s6 = 0 mm
Die Programmauswahleinheit 11 bestimmt aus den Massen s1 ... s6 die Charakteristika KT, KB und KV für die Geometrie des Werkstücks 103 zu:
Die Steuereinheit 12 ermittelt aus diesen Charakteristika die Programmnummer PRG121 für die Vorderseite und die Programmnummer PRG121 für die Rückseite (Schritt 27) und stellt die Beschichtungsparameter P1 ... P9 für das Werkstück 103 entsprechend ein (Schritt 28).The
Das in
- s1 = 150 mm
- s2 = 480 mm
- s3 = 90 mm
- s4 = 130 mm
- s5 = 0 mm
- s6 = 0 mm
- s1 = 150 mm
- s2 = 480 mm
- s3 = 90 mm
- s4 = 130 mm
- s5 = 0 mm
- s6 = 0 mm
Die Programmauswahleinheit 11 bestimmt aus diesen Massen s1 ... s4 die Charakteristika KT, KB und KV für die Geometrie des Werkstücks 104 zu:
Die Steuereinheit 12 ermittelt aus diesen Charakteristika die Programmnummer PRG232 für die Vorderseite und die Programmnummer PRG231 für die Rückseite und stellt die Beschichtungsparameter P1 ... P9 für das Werkstück 104 entsprechend ein.The
Das in
- s1 = 140 mm
- s2 = 480 mm
- s3 = 60 mm
- s4 = 130 mm
- s5 = 20 mm
- s6 = 210 mm
- s1 = 140 mm
- s2 = 480 mm
- s3 = 60 mm
- s4 = 130 mm
- s5 = 20 mm
- s6 = 210 mm
Die Programmauswahleinheit 11 bestimmt aus diesen Massen s1 ... s4 die Charakteristika KT, KB und KV für die Geometrie des Werkstücks 105 zu:
Die Steuereinheit 12 ermittelt aus diesen Charakteristika die Programmnummer PRG232 für die Vorderseite und die Programmnummer PRG231 für die Rückseite und stellt die Beschichtungsparameter P1 ... P9 für das Werkstück 105 entsprechend ein.The
Sobald das Werkstück den Beschichtungsbereich erreicht, veranlasst die Steuereinheit 12, dass die zu dem Werkstück passenden Beschichtungsparameter P1 ... P9 eingestellt werden und das Werkstück optimal beschichtet wird.As soon as the workpiece reaches the coating area, the
Mit dem erfindungsgemässen Verfahren können die verschiedensten Werkstückprofile automatisch erfasst und die dafür optimalen Beschichtungsparameter ermittelt werden.With the method according to the invention, a wide variety of workpiece profiles can be detected automatically and the optimum coating parameters can be determined.
Die in den Figuren dargestellten Werkstückprofile sind lediglich Beispiele. Das Werkstück kann auf der Vorderseite und der Rückseite auch mehr als jeweils eine Vertiefung aufweisen. Mit dem erfindungsgemässen Verfahren lassen sich annähernd beliebig viele Vertiefungen im Werkstück vermessen. Die Anzahl der erfassten Vertiefungen ist ein Mass für die Komplexität des Werkstücks und kann als weiterer Beschichtungsparameter bei der Auswahl der geeigneten Programmnummer berücksichtigt werden. Wenn beispielsweise weniger als fünf Vertiefungen auf einer Seite des Werkstücks ermittelt werden, kann das Werkstück als wenig komplex eingestuft werden. Werden fünf oder mehr Vertiefungen auf einer Seite des Werkstücks ermittelt, kann das Werkstück als komplex eingestuft werden.The workpiece profiles shown in the figures are only examples. The workpiece may also have more than one recess on the front and the back. With the inventive method Almost any number of depressions in the workpiece can be measured. The number of recesses recorded is a measure of the complexity of the workpiece and can be taken into account as a further coating parameter when selecting the appropriate program number. For example, if less than five indentations are detected on one side of the workpiece, the workpiece can be considered to be of little complexity. If five or more recesses are detected on one side of the workpiece, the workpiece can be classified as complex.
Die Erfassung des Werkstückprofils kann unmittelbar vor der Beschichtungsstation oder auch weit davor erfolgen. Erfolgt die Erfassung des Werkstückprofils weit vor Beschichtungsstation, wird unter anderem auch sichergestellt, dass die Sensoren nicht durch das überschüssige Pulver verschmutzen. Die Reihenfolge in der die verschiedenen Werkstücke zur Beschichtungsstation gelangen, spielt keine Rolle. Die Steuereinheit 12 merkt sich die Reihenfolge, in der die Werkstücke erfasst wurden und kann dies dann beim Beschichten berücksichtigen.The detection of the workpiece profile can be done immediately before the coating station or well before. If the workpiece profile is detected well in front of the coating station, it is also ensured, among other things, that the sensors do not become contaminated by the excess powder. The order in which the various workpieces reach the coating station, does not matter. The
Die Erfassung der Breite, der Tiefe und der Vertiefungen kann auch auf die folgende Art und Weise erfolgen.The detection of the width, the depth and the depressions can also be done in the following manner.
Die beiden Sensoren 3 und 5 sind als optische Zeilenscanner ausgebildet und erfassen während der Zeitdauer T, während der das Werkstück 100 an ihnen vorbei transportiert wird, nicht nur punktweise sondern zeilenweise das Werkstück 100. Auf diese Weise entsteht zum Zeitpunkt t1 der Abtastung das gesamte Abtastprofil A(t1, d) des Werkstücks. Der Sensor 3 liefert als Abtastprofil A(t1, d3) die Messpunkte
Der Sensor 5 liefert als Abtastprofil A(t1, d5) die Messpunkte
Diese beiden Abtastprofile A(t1, d3) und A(t1, d5) werden der Auswerteeinheit 10 zugeführt. Im Unterschied zur ersten Ausführungsform ist hier kein separater Sensor 7 zur Erfassung der Werkstückbreite vorhanden. Aus der Messreihe A(t1, d3) kann die Auswerteeinheit 10 sowohl die Gesamttiefe s1 als auch die Gesamtbreite s2 des Werkstücks 100 ermitteln. Aus dem Abtastprofil A(t1, d3) ermittelt die Auswerteeinheit 10 zusätzlich die Geometrie der Vorderseite des Werkstücks 100. Aus dem Abtastprofil A(t1, d5) ermittelt die Auswerteeinheit 10 die Geometrie der Rückseite des Werkstücks 100.These two scanning profiles A (t1, d3) and A (t1, d5) are fed to the
Die Zuordnung der Masse zu den jeweiligen Klassen KT, KB und KV und die Bestimmung der Programmnummer PRG erfolgt vorteilhafter Weise auf die oben unter Ausführungsform 1 beschriebene Weise.The assignment of the mass to the respective classes KT, KB and KV and the determination of the program number PRG is advantageously carried out in the manner described above under
Hierbei wird die Breite des Werkstücks mit einem Inkrementalgeber ermittelt. Dazu kann der Sensor 7 als Inkrementalgeber ausgebildet sein. Sobald sich die Transporteinrichtung bewegt, erzeugt der Inkrementalgeber Impulse oder Inkremente. Wenn das an der Transporteinrichtung 2 hängende Werkstück 100 den Sensor 3 passiert, wird ein Startimpuls ausgelöst, der das vordere Ende des Werkstücks signalisiert. Wenn das hintere Ende des Werkstücks den Sensor 3 passiert, wird ein Endimpuls ausgelöst, der das hintere Ende des Werkstücks signalisiert. Anhand der Anzahl der vom Inkrementalgeber gelieferten Inkremente, die zwischen einem Start- und einem Endimpuls liegen, kann auf einfache Weise die Breite des Werkstücks errechnet werden. Unter Umständen kann sogar die Anzahl der zwischen dem Start- und dem Endimpuls auftretenden Inkremente genügen, um daraus auf die Breite des Werkstücks zu schliessen. In diesem Fall hat das Werkstück dann eine Breite, die der Anzahl der zwischen dem Start- und dem Endimpuls auftretenden Inkremente entspricht. Das Mass für die Werkstückbreite ist dann die Anzahl der Inkremente.The width of the workpiece is determined with an incremental encoder. For this purpose, the
Die Erfassung der Tiefe und der Vertiefungen des Werkstücks kann auf die oben unter Ausführungsform 1 oder 2 beschriebenen Art erfolgen.The detection of the depth and the recesses of the workpiece can be carried out in the manner described above under
Die Zuordnung der Masse zu den jeweiligen Klassen KT, KB und KV und die Bestimmung der Programmnummer PRG erfolgt vorteilhafter Weise auf die oben unter Ausführungsform 1 beschriebene Weise.The assignment of the mass to the respective classes KT, KB and KV and the determination of the program number PRG is advantageously carried out in the manner described above under
Die vorhergehende Beschreibung der Ausführungsbeispiele gemäss der vorliegenden Erfindung dient nur zu illustrativen Zwecken und nicht zum Zwecke der Beschränkung der Erfindung. Im Rahmen der Erfindung sind verschiedene Änderungen und Modifikationen möglich, ohne den Umfang der Erfindung sowie ihre Äquivalente zu verlassen. So kann beispielsweise bei der oben beschriebenen Ausführungsform 2 der in
Die einzelnen Komponenten beziehungsweise Verfahrensschritte der oben beschriebenen Ausführungsformen können auch auf eine andere als in den Ausführungsformen 1 bis 3 beschriebene Weise miteinander kombiniert werden.The individual components or method steps of the embodiments described above can also be combined with one another in a manner other than described in the
Als Werkstücke eignen sich insbesondere längliche Profile mit im Wesentlichen über die Länge gleichbleibendem Querschnitt, wie zum Beispiel Konstruktionsprofile für Wintergärten.In particular elongate profiles are suitable as workpieces with substantially constant cross-section over the length, such as construction profiles for conservatories.
- 11
- Beschichtungsanlagecoating plant
- 22
- Transporteinrichtungtransport means
- 33
- Sensorsensor
- 44
- Halterungbracket
- 55
- Sensorsensor
- 66
- Halterungbracket
- 77
- Sensor zur PositionserfassungSensor for position detection
- 88th
- Pulversprühpistolepowder spray
- 99
- Pulversprühpistolepowder spray
- 1010
- Auswerteeinheitevaluation
- 1111
- ProgrammauswahleinheitProgram selection unit
- 1212
- Einheit zur Ermittlung der ParameterUnit for determining the parameters
- 1313
- Steuergerät für die Pistole 9Control unit for the gun 9
- 1414
-
Steuergerät für die Pistole 8Control unit for the
gun 8 - 1515
- LinearhubgerätLinearhubgerät
- 20 - 3020 - 30
- Verfahrensschrittesteps
- 100100
- Werkstückworkpiece
- 101101
- Werkstückworkpiece
- 102102
- Werkstückworkpiece
- 103103
- Werkstückworkpiece
- 104104
- Werkstückworkpiece
- 105105
- Werkstückworkpiece
- 106106
- Werkstückworkpiece
- 107107
- Werkstückworkpiece
- d3d3
-
Distanz zwischen Sensor 3 und WerkstückDistance between
sensor 3 and workpiece - d5d5
-
Distanz zwischen Sensor 5 und WerkstückDistance between
sensor 5 and workpiece - K1K1
- Klasse für die TiefeClass for the depth
- K2K2
- Klasse für die BreiteClass for the width
- Pos xPos x
- Position in x-RichtungPosition in x-direction
- PRG PPRG P
- Programmnummer PProgram number P
- P1P1
-
Beschichtungsparameter 1
Coating parameters 1 - Pnpn
- Beschichtungsparameter nCoating parameters n
- s1s1
- Tiefe des WerkstücksDepth of the workpiece
- s2s2
- Breite des WerkstücksWidth of the workpiece
- s3s3
- Vertiefung im WerkstückRecess in the workpiece
- s4s4
- Breite der VertiefungWidth of the recess
- s5s5
- Vertiefung im WerkstückRecess in the workpiece
- s6s6
- Breite der VertiefungWidth of the recess
- TT
- ZeitraumPeriod
- TRTR
- Transportrichtungtransport direction
Claims (15)
- A method for coating a workpiece with powder by means of a powder spray gun,- wherein the depth (s1) of the workpiece (100) is measured,- wherein the width (s2) of the workpiece (100) is measured,- wherein recesses (s3, s4), if any are possibly present in the workpiece (100), are measured,- wherein coating parameters (P1 - Pn) are determined by means of an evaluation and control unit (10 - 12) based on the depth (s1), the width (s2) and the recesses (s3, s4), and- wherein the powder spray gun (8) is operated with the coating parameters (P1 - Pn) determined for the workpiece (100) and the workpiece (100) is coated.
- The method according to claim 1,
wherein the coating parameters are the high voltage (P1) and/or the spray current (P2) and/or the atomized air (P3) and/or the amount of powder (P4) and/or the triggering of the powder spray gun (P5) and/or the conveying air (P6) and/or the dosing air (P7) and/or the distance (P8) between the workpiece (100) and the powder spray gun (8) and/or the vertical position (P9) of the powder spray gun (8) and/or whether the workpiece is precoated and/or whether the side in question is the visible side of the workpiece and/or whether the side in question is the rear side of the workpiece and/or the powder type and/or the conductivity of the workpiece and/or the transport speed of the workpiece. - The method according to claim 1 or 2,
wherein the measured depth (s1) of the workpiece (100) is assigned to one out of a plurality of classes (KT1) for the depth. - The method according to any one of claims 1 to 3,
wherein the measured width (s2) of the workpiece (100) is assigned to one out of a plurality of classes (KB1) for the width. - The method according to any one of claims 1 to 3,
wherein the recess (s3, s4) of the workpiece (100) is assigned to one out of a plurality of classes (KV3) for the recess. - The method according to any one of claims 1 to 5,
wherein the recess is determined based on the ratio of the recess depth (s3) to the recess width (s4). - The method according to any one of the preceding claims,
wherein the width of the workpiece is determined by means of an incremental encoder. - The method according to claim 7,
wherein the width of the workpiece is determined by means of the increments that are present between a start pulse and an end pulse and are supplied by the incremental encoder. - The method according to any one of claims 3, 4 or 5, wherein, from the class (KT1) for the depth and/or the class (KB1) for the width and/or the class (KV3) for the recesses, a program number (PRG) is automatically selected from a set of program numbers, wherein specific coating parameters (P1 - Pn) are linked with each program number.
- The method according to claim 9,
wherein the coating parameters (P1 - Pn) for the powder spray gun (8) are determined by means of the program number (PRG). - The method according to any one of the preceding claims,
wherein the recesses (s3, s4) on the front side and the recesses (s5, s6) on the rear side of the workpiece (100) are measured. - A powder spray coating system which can be operated utilizing the method according to any one of the preceding claims 1 to 11,- wherein a measuring device (3, 7) is provided for measuring the depth (s1) and the width (s2) of the workpiece (100),- wherein an evaluation unit (10, 11) is provided for determining the coating parameters (P1 - Pn),- wherein a powder spray gun (8) is provided for coating the workpiece (100),- wherein a control unit (12) is provided for operating the powder spray gun (8) with the coating parameters (P1 - Pn).
- The powder spray coating system according to claim 12,- wherein a transporting device (2) is provided for the workpiece (100),- wherein the measuring device (3) for the depth (s1) is arranged and operable in such a way that it measures the depth (s1) of the workpiece (100) at the top of the workpiece.
- The powder spray coating system according to any one of claims 12 or 13,
wherein the measuring device comprises an incremental encoder (7) in order to measure the width (s2) and/or the position (Pos x) of the workpiece (100). - The powder spray coating system according to claim 13 or 14,
wherein the measuring device (3) for the depth (s1) comprises a distance measuring sensor, a line scanner, a turning steel scanner, or a camera.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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EP12405107.9A EP2712680B1 (en) | 2012-09-27 | 2012-09-27 | Method for coating a workpiece by means of a powder spray gun and powder coating assembly |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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EP12405107.9A EP2712680B1 (en) | 2012-09-27 | 2012-09-27 | Method for coating a workpiece by means of a powder spray gun and powder coating assembly |
Publications (2)
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EP2712680A1 EP2712680A1 (en) | 2014-04-02 |
EP2712680B1 true EP2712680B1 (en) | 2015-08-12 |
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Cited By (1)
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RU2689604C2 (en) * | 2015-02-17 | 2019-05-28 | Эксель Эндюстри | Method for application of coating material on component, which moves on conveyor and installation for coating material application |
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ITUA20162328A1 (en) * | 2016-04-05 | 2017-10-05 | Sat Surface Aluminium Tech S R L | PLANT AND PROCEDURE FOR PAINTING PROFILES |
TR202020493A2 (en) * | 2020-12-14 | 2022-06-21 | Si̇stem Tekni̇k Maki̇na Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ | DISTANCE ADJUSTABLE WORKPIECE PAINTING SYSTEM AND METHOD |
DE102020134087A1 (en) * | 2020-12-18 | 2022-06-23 | Gema Switzerland Gmbh | PLANT FOR COATING OBJECTS WITH COATING MATERIAL AND METHOD FOR COATING OBJECTS WITH COATING MATERIAL |
CN112791876B (en) * | 2020-12-31 | 2022-09-09 | 河南海螺嵩基新材料有限公司 | Aluminum profile surface powder spraying uniformity control device and control method |
CN113399139A (en) * | 2021-07-05 | 2021-09-17 | 深圳市华信一机械有限公司 | Full-automatic electrostatic powder spraying production line |
CN114700195B (en) * | 2022-03-11 | 2023-04-18 | 百家丽(中国)照明电器有限公司 | Workpiece surface electrostatic spraying device and process |
CN117217498B (en) * | 2023-11-07 | 2024-03-22 | 广州泽亨实业有限公司 | Powder management method and system based on workpiece contour surface size identification |
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US5718767A (en) | 1994-10-05 | 1998-02-17 | Nordson Corporation | Distributed control system for powder coating system |
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RU2689604C2 (en) * | 2015-02-17 | 2019-05-28 | Эксель Эндюстри | Method for application of coating material on component, which moves on conveyor and installation for coating material application |
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